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Trimac Industries - manufacturer of finishing systems, ovens and pretreatment & part washers
"Many
companies RESELL catalytic,
few can
MAKE it”
The Gas-Cat™ Infra-Red
catalytic emitter (heater) was pioneered within the Infra-Red Technologies
product line. Over the Gas-Cat™'s almost 20
years history, over 10,000 emitters have been produced, most of which are
still in operation today.
Trimac designs all forms of radiant technology as well as convection. For
the majority of difficult curing or finishing applications, catalytic infrared
however provides the safest, most energy efficient and accurately controllable
heat source producing the optimum finish on your product.
Trimac Industries is one of only a handful of companies worldwide
with the capability of actually manufacturing catalytic emitters. Benefiting
from our years of experience solving difficult finishing challenges, Trimac
best understands how to apply and control the radiant heat to ensure our
customers produce the best finished product. In addition, since we are the
only manufacturer worldwide of catalytic emitters who also manufactures aqueous
washers, Trimac's breadth of knowledge and range of capabilities are unique
to the industry.
The Gas-Cat™ uses a safe, flameless, proprietary technology to
produce infrared energy through a catalytic reaction. This means NO
FLAME is used to generate heat. Convection ovens, by contrast,
use a flame to heat the surrounding air to raise the surface temperature
of the product. Because of the flameless construction, the Gas-Cat™ can
be ordered certified to be explosion-proof, meeting Factory Mutual and
Canadian Standards Association insurance standards for use in Class 1,
Division 2 environments.
Infrared uses light energy (much like solar energy) to heat products
and penetrate and cure the coatings throughout. The infrared
waves excite molecules within a product (thus generating heat) but pass,
generally undisturbed thorough the surrounding air. Infrared energy is
generated one of three ways, catalytic, electric or gas-
fired. Catalytic infrared
is a medium to long wave energy and is typically considered the best all-around fit
because of its controllability, speed, safety, economical energy
usage and superior curing capabilities. Electric generally produces
short to medium wave energy which is best suited for products needing
a high, intense heat or extremely high volume, fast production
environments. Electric infrared however operates at a considerably
higher cost because of the greater utility consumption. Gas-fired
infrared can also produce a similar medium to long wave energy
like catalytic, but uses a flame to produce heat and so has some
of the same limitations as gas convection.
Beyond the safety and energy savings of using catalytic infrared,
the Gas-Cat™ typically
requires 1/3 of the floor space needed to cure with convection heat. Because
infrared heat is directly absorbed by the part and energy is not wasted by heating
the surrounding air, parts therefore get to temperature quicker. This means that
lines can run faster or cure times can be shorter. The result is you pay for
less energy which reduces overall operating costs.
Gas-Cat™ usage
can also result in a higher gloss and brighter finish for finished
products. In liquid paint applications, the infrared
energy allows solvents and water to be driven out of paint before
a skin can form. In powder applications, gelling and cross-linking
of the powder occurs at a faster rate and prevents powder blow-off
from air movement.
Catalytic heat is created
by a chemical reaction using our proprietary Gas-Cat™ catalyst. This
catalyst (a substance that alters the rate of a chemical reaction)
coats the pad within the emitter and during operation it chemically
reacts with the fuel, creating controllable face temperatures from
250°F to 1000°F, depending on configuration.
• To
begin the process, an electric heating element or calrod is turned
on to preheat the catalyst coated pad
• Once the catalyst pad reaches 250°F
(the temperature that will self-sustain the chemical reaction with
the fuel gas to convert it to energy) measured by the thermoswitch,
a signal is sent to the control panel
• Once a heater is at
temperature, the safety shut-off valve allows the gas to flow to
the heater
• The combination of oxygen and the fuel gas
in the presence of the catalyst impregnated pad creates the chemical
reaction which generates the heat
• Once this process has stabilized,
the electric heating element is turned off
• The main byproducts of this chemical reaction are H²O
and CO².
• Due to the flameless construction of a Gas-Cat™ emitter,
they can safely be specified and have been certified for use in hazardous
locations by FM and CSA
• Stainless steel housing, framing & rivets Lengthens life and improves performance of heater
• Welded construction Redundant structural
integrity & gas
tight seal
• 4” heater height Significantly less heat loss out back of heater
• 1'
center structural ribs on heaters Prevents width warping affecting gas seal & cure control
• Lateral
stiffening ribs Prevents length warping affecting gas seal & cure control
• ½” thick
catalytic pad Improves uniform heat transfer
• Contoured
gas dispersion tube Uniform gas flow for even heat distribution
• Low
watt density electrical rods Reduces heater burnout & increases life
• Recompact heating elements after contouring Improves heat transfer & eliminates potential for arcing
• Higher
operating pressures Improved controllability
of temperature
• No flame Safe for Class 1, Div. 2, Group D Hazardous locations
• Heats objects faster Reduces time and space required
• Rapid cure temperature Minimal powder blow-off
• Can cure in 1/3 the space Significant gas and space savings
• Oven zoning capability Control over energy usage for individual part cure times
• Produces virtually no NOx or CO Reduces toxic emissions and environmental expense
• Only by-products are water vapor & CO² Simplifies regulatory compliance
• Lower flue emissions Less conditioned plant air lost from ventilation
• Fuel utilized more efficiently Less make-up air required (less dirt & energy usage)
• Accurate temperature control Fewer incidences of skinning and popping
• Redundancy Multiple heaters
permit maintenance during operation
SIZE
BTUH
WATTAGE
B 6-12
3,000
85
B 6-24
6,000
180
B12-12
6,000
200
B12-18
9,000
200
B12-24
12,000
400
B12-30
15,000
400
B12-36
18,000
600
B12-42
21,000
600
B12-48
24,000
800
B12-60
30,000
1000
B12-72
36,000
1000
B18-18
13,500
400
B18-24
18,000
400
B18-30
22,500
400
B18-36
28,000
900
B18-42
31,500
900
B18-48
37,000
1200
B18-54
40,500
1200
B18-60
45,000
1500
B18-66
50,000
1500
B18-72
54,000
1500
B24-24
24,000
1200
B24-36
36,000
1200
B24-42
42,000
1200
B24-48
50,000
1600
B24-54
54,000
1600
B24-60
60,000
2000
B24-72
72,000
2000
GAS-CAT™ EMITTERS
CAN BE ORDERED:
• Standard
• Standard
with Explosion Proof
• With MR4 (Manual
Start Device)
• Explosion Proof
with MR 4
Trimac
Industries Repairs & Remanufactures all
emitter brands
Curing
Powder coatings
Water-borne paints
Solvent-based paints
Plastic and latex surfaces
Lacquered metal components
Silkscreen prints
Boat and shoe adhesives
Plastisol coated parts
Drying
Water evaporation
Fiberglass gelcoats and
resins
Washed, dyed or finished textiles
Skins and color-sprayed leathers
Ores
Ink drying
Adhesives and surface sealing
Metallic inks
Shaping
Thermo-forming
Vacuum forming
Pressure forming
Setting twist in synthetic fibers
Setting nylon and perlon
threads
Preheating rubber sheeting
for extrusion
Heating papermache
for molding or pressing
Shrink wrapping
Infrared heat
works like the sun does heating the earth or evaporating the
water in a lake. Flameless Gas-Cat™ catalytic Infra-Red is
a directed, controllable source of medium to long wavelengths.
At these wavelengths, as much as 96% of the energy is absorbed
by the paint or other medium when the heat waves contact it.
Natural gas or LP fuels are introduced to the heated surface of the catalyst
pads in the oven. The gas contacts the platinum catalyst and is oxidized at the
surface of the heater by chemically reacting with the air at the surface of the
pad to generate a temperature from 250° to 1000° Fahrenheit, without
generating a flame. The infrared waves penetrate the coating surface and heat
the coating throughout its thickness, leaving the outside surface porous enough
to allow solvent and/or water to escape before the surface is cured.
Infrared heat drives the solvents and water
out of the paint before the surface cures, and results in a higher
gloss, brighter finish.
Infrared heat is inexpensive to operate compared
to a convection oven when performing the same function. Unlike
a convection oven, infrared passes through air without heating
it, only solid materials are heated. Since the ambient air in
an infrared oven is not heated, thinner, less expensive insulation
can be used for oven enclosures. Although some energy is conducted
to the base material when heated by infrared, all of the base
is not raised to the surface temperature, thereby saving energy
costs.
Infrared is an excellent heat source for gelling
and curing powder. Since circulating air is not the source of
heat, the powder is not blown off parts nor is there cross contamination
from other colors. As a result, a better finish is achieved.
The products of chemical reaction are CO2
and water vapor. Therefore, exhaust is minimal, reducing the
amount of makeup air that must be heated.
